Offsite Manufacturing of Timber-Frame Woodfibre Insulated Construction Systems for Nearly-to-Zero Carbon Dwellings in Wales, UK

This paper discusses some of the findings of a knowledge transfer partnership (KTP) research project that has refined the materials and processes of offsite manufactured timber-frame wood fibre insulated construction systems for nearly-to-zero embodied and operational carbon dwellings in Wales, UK. Context to the need for reducing carbon emissions is given from a UK and Wales perspective and targets for 60% of housing to be constructed from timber in Wales. The methodology presented outlines a step-by-step process from material supply to fully manufactured two-dimensional (2D) closed panel systems for walls, roofs, and floors, using equipment that only three manufacturers use in the UK for fibre-based insulation. The outcomes of the methodological implementation have led to full scale production of the 2D prefabricated panels systems for Gwynfaen, Wales’ largest zero-carbon social housing development. The next steps are discussed which include performance testing of the panel systems in manufacture and during construction.